Packaging systems, apparatus and method therefore

ABSTRACT

A system for monitoring the condition of a packaging machine during operation and diagnosing potential problems in the performance of the machine. The system comprises an input device, an output device and a processing unit that supports a user interface presented by the output device. The processing unit is arranged to permit a user, when in use, to input via the user interface a number of pre-determined parameters to measure one or more elements or assemblies in the machine, to receive information from one or more sensors measuring the element or assembly and to analyze the information with the parameter to render via the output device a signal.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.11/379,672, filed Apr. 21, 2006, which is a divisional U.S. applicationSer. No. 10/807,506, filed Mar. 19, 2004, which is a continuation ofInternational Application No. PCT/US02/29862, filed Sep. 20, 2002, whichclaims priority to GB Application No. 0122681.0, filed Sep. 20, 2001,the contents of the aforementioned applications are hereby incorporatedby reference.

BACKGROUND OF THE INVENTION

The present invention relates to a system for identifying abnormaloperation of a packaging machine, for example, of the type used topackage consumer products such as cans and bottles into multiplepackaged cartons. The present invention also relates to a method ofidentifying abnormal operation of a packaging machine and a diagnosticapparatus for a same purpose.

The majority of known packaging machines are dedicated machines whichcan construct only one size or type of carton. Therefore, modernbottling plants are required to use several packaging machines topackage different carton types. Some packaging machines are capable ofpackaging different types or sizes of cartons. All such machines requireadjustment when switching from one size or type of carton to another.

Packaging machines will typically package approximately 60,000 to200,000 articles per hour and are required to run continuously for longperiods of time. A machine failure or scheduled maintenance means thatthe machine cannot be used (known as “down time”), which is an expensivedelay in a bottling plant. Such a delay will usually result in down timefor the entire bottling line, not just the packaging machine,particularly if problems have arisen.

SUMMARY OF THE INVENTION

According to a first aspect of the present invention, there is provideda system for identifying abnormal operation of a packaging machine, thesystem comprising: a sampling unit arranged to sample a signal issued,when in use, to a servo-motor, the signal corresponding to torque valuesof the servo-motor; a spectrum analyzer for generating a spectralanalysis of the sampled signal; a processing unit coupled to a storagedevice for storing a characterization of a mechanical element coupled tothe servo-motor and corresponding to a state of operation, thecharacterization corresponding to at least one predetermined value foreach of at least one frequency of the signal; wherein the processingunit is arranged to determine, when in use, abnormal operation of themechanical element using the spectral analysis of the sampled signal andthe characterization of the mechanical element.

Preferably, the system further comprises the state of normal operation.

Preferably, the processing unit is arranged to determine an actualsampling rate of the sampling unit.

Preferably, the actual sampling period is derived from an expectedsampling period, an expected speed and an actual position of theservomotor.

Preferably, a correction factor is calculated from the actual samplingperiod and the expected sampling period for applying to the sampledsignal.

Preferably, the characterization is either learnt by the system orextracted from a database containing rules.

Preferably, when characterization is based upon rules, fuzzy logic isused to quantify the abnormal operation of the mechanical element.

Preferably, the system further comprises the at least one predeterminedvalue for each of the at least one frequency of the signal embodied inat least one respective rule applicable, when in use, to the spectralanalysis of the signal.

According to a second aspect of the present invention, there is provideda diagnostic apparatus for identifying abnormal operation of a packagingmachine, the apparatus comprising: a processing unit arranged to receivea sampled signal issued, when in use, to a servo-motor, the signalcorresponding to torque values of the servo-motor; wherein theprocessing unit is coupled to a storage device for storing acharacterization of a mechanical element coupled to the servo-motor, thecharacterization comprising at least one predetermined valuecorresponding to a plurality of the torque values of the servo-motor ina condition of normal operation; and the processing unit is arranged todetermine, when in use, abnormal operation of the mechanical elementusing the sampled signal and the characterization of the mechanicalelement.

According to a third aspect of the present invention, there is provideda method of identifying abnormal operation of a packaging machine, themethod comprising the steps of: sampling a signal issued to aservo-motor, the signal corresponding to torque values of theservo-motor; retrieving a previously stored characterization of amechanical element coupled to the servo-motor, the characterizationcomprising at least one predetermined value corresponding to a pluralityof the torque values of the servo-motor in a condition of normaloperation; and determining abnormal operation of the mechanical elementusing the sampled signal and the characterization of the mechanicalelement.

In an embodiment of the invention, there is provided a computer programelement comprising: computer program means to make a computer executethe method as set forth in accordance with the third aspect of thepresent invention.

Preferably, the computer program element is embodied on a computerreadable medium.

According to a fourth aspect of the present invention, there is provideda system for monitoring the condition of a packaging machine duringoperation and diagnosing potential problems in the performance of themachine, the system comprising an input device, an output device and aprocessing unit that supports a user interface, the processing unitbeing arranged to permit a user, when in use, to input via the userinterface a number of predetermined parameters to measure one or moreelements or assemblies in the machine, to receive information from oneor more sensors measuring the element or assembly and to compare theinformation with the parameter to render via the output device an outputsignal.

According to an optional feature of the fourth aspect of the inventionthe output signal is a warning message displayed on the output device.Optionally, the output signal actuates an auto-correction device.

Preferably, the output signal is a message warning the operator aboutscheduled maintenance.

According to a fifth aspect of the present invention, there is provideda programmed computer for generating control data for controlling apackaging machine, comprising memory having at least one region forstoring computer executable program code, and a processor for executingthe program code stored in the memory, wherein the program codeincludes: code to receive input data corresponding to a number ofmeasurements made respectively based upon measurements recorded by oneor more sensors monitoring an element or assembly of the machine; codeto generate a comparison between the input data and stored datacorresponding to pre-determined parameters for the element or assembly;code to generate output data for the packaging machine when the inputdata does not correspond to the stored data.

According to a sixth aspect of the present invention, there is provideda computer readable medium having computer executable software codestored thereon, the code being for the monitoring of a packaging machineand comprising: code to receive input data corresponding to a number ofmeasurements made respectively based upon measurements recorded by oneor more sensors monitoring an element or assembly of the machine; codeto generate a comparison between the input data and stored datacorresponding to pre-determined parameters for the element or assembly;code to generate output data for the packaging machine when the inputdata does not correspond to the stored data.

It is thus possible to provide a system for identifying abnormaloperation of a packaging machine that overcomes the technical andcommercial disadvantages of known systems. In particular, it is possibleto provide information to an operator on various aspects of thepackaging machine to provide preventative maintenance, conditionalmaintenance for likely problems prior to any catastrophic failure of themachine.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments will now be described, by way of example only withreference to the following drawings in which:

FIG. 1 is a block diagram of a control system in accordance with a firstembodiment of the invention;

FIG. 2 is a flow diagram of a control system for preventativemaintenance in accordance with one embodiment of the present invention;

FIG. 3 is a flow diagram of a control system for conditional maintenanceand re-engineering assemblies in accordance with one embodiment of theinvention;

FIG. 4 is a schematic diagram of part of a packaging system including adiagnostic system constituting another embodiment of the presentinvention;

FIG. 5 is a flow diagram of a data acquisition method for use with thediagnostic system of FIG. 4; and

FIGS. 6 and 7 are flow diagrams of two parts of a data processing methodfor use with the diagnostic system of FIG. 4 and/or in conjunction withthe method of FIG. 5.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Throughout the following description, identical reference numerals shallbe used to identify like parts.

Referring to the drawings and in particular FIG. 1 there is shown asystem for integrating electrical and mechanical data and informationtechnology in a packaging machine for improving productivity byforecasting and scheduling maintenance so that down time will notadversely impact production and market needs. The system can be employedon new machinery or fitted to existing packaging machines that have GENII or GEN III architecture (that is, architecture utilizing differentdeployment of PC's and PLC'S), on a retrofit basis.

The system is used to improve the machine efficiency by enabling anoperator to perform (i) preventative maintenance, (ii) conditionmaintenance, and (iii) re-engineer assemblies to improve performance.

The system comprises a controller 100 fitted to a packaging machine (notshown), but is usually incorporated into the existing control means. Thecontroller 100 comprises an input device 102, an output device 104 and aprocessing unit 106 that supports a user interface presented by theoutput device 104.

To use the system in preventative maintenance mode, as shown in FIG. 2,a user will input pre-determined parameters for the maintenance of keyassemblies and elements of the packaging machine, for example machinesanitation, replacement of vacuum cups, replacement of bearings andlubrication 200. The parameters are based upon number of cartons usedand hours of production, so that the next scheduled maintenance isdetermined by the controller 106. The controller will record productiondata 202 and compare it to the parameters 204. At the point when thenext scheduled maintenance for one or more of the elements is required,the controller 106 will output a message to the display 104, alertingthe operator to the element or assembly to be maintained 206.

In order to perform condition maintenance, the system includes elementsto diagnose problems. To achieve this, there further comprises a numberof sensors 108 for monitoring various physical parameters. The physicalparameters can be processed in order to provide additional parameters,as shown in FIG. 1. For example, a signal corresponding to a torque of amotor can undergo spectral analysis, amplitude at a specific frequencyrevealed by the spectral analysis being of use as a parameter in adiagnostic process. Whilst, in at least one example of the presentinvention contained herein, sensors are employed in order to probephysical parameters, direct evaluation of physical parameters by adevice constituting a sensor is possible. An example of such a sensor isa servomotor as it is able to provide a signal corresponding to thetorque of the servomotor.

For example, to monitor the various chain or belt assemblies, the chaintension 110 is monitored by measuring and processing the torque of theservomotor driving each chain.

Preferably, the lubrication 112 is analyzed by measuring the servo motortorque to diagnose for poor lubrication.

This system is also used to diagnose a ‘tight spot’ 114. In a packagingmachine, the ‘tight spot’ occurs when the package binds with one of theguides or moving parts on a conveyor or chain due to glass, paper, dust,glue, etc. which will result in the conveyor chain/belt jolting.

Sensors may also be used to monitor one or more of chain wear 116,bearing wear 118 and/or belt wear 120, again by monitoring the servomotor torque to diagnose one assembly chains or belts. Referring to FIG.3, as regards the bearing wear analysis, a noise detection device 300can be used in addition to, or as an alternative, to locate theparticular position of a worn bearing.

Optionally, visual information 302 about the condition of the machine,for example monitoring star wheel condition, jam induced with anarticle, is recorded by high speed cameras and fed to the controller 100where a file is generated and saved in the hard disk of a PC within thesystem.

In some embodiments, the signal from the sensor 108 will be filteredthrough known electronic filters 304 to reduce the background noise inthe signal.

Pre-programmed parameters 306 for the various elements being monitoredare entered into the controller, by pre-programming the system or bymanually inputting the parameters in-situ. The parameters can be used asinputs for a computing system in order to evaluate the level of aspecific problem, for example the chain tension evaluated using specificparameters and compared with upper and lower tolerance limits.

Information from the servo motor sensors 308, detected noise from thenoise detection device 300 and visual information 302 is input into thecontrol processor 106 and compared to the pre-programmed parameters,input for each servo motor or machine assembly. If the input measurementfrom the sensors is not within a predetermined range or tolerance limit,then the control processor 106 will issue an alert message 310 and themeasurement compared to various known parameters for faults in themachine so as to display the fault. For example, if a chain is subjectedto the tight spot, the torque measurement will indicate that there are anumber of spikes at regular intermittent intervals and the processorwill display an alert message. If the chain tension deviates eitherabove or below the predetermined range, this will indicate the tensionof the chain is too loose or too tight. Again, a message is communicatedto the user via the display.

The operator will then intervene to correct the problem, or will monitorit more closely until scheduled maintenance.

Optionally, the controller 100 may include a fail safe monitoringparameter so that if there is a serious problem, for example themeasurements exceed pre-programmed safe working parameters, thecontroller will output a signal to automatically shut down the machine314.

With certain parameters it is possible to automatically correct 312 thedefect and various auto-correction devices are employed in the machine.In the illustrated embodiment of FIG. 1, the system includes a chaintensioner 122 controlled by the controller to be automaticallyintroduced or moved thereby to increase or decrease the tension of thechain so as to return the servo-motor torque to within thepre-programmed range. Similarly, if it appears that the lubrication hasdeteriorated then micro-sprayers 124 are switched on by the controller100 to lubricate the chains automatically and without the need forturning the machine off.

The information recorded by the controller 100 is stored on hard disc orother storage medium to be used to monitor the performance of themachine remotely from the packaging plant. Remote monitoring is achievedby coupling the controller 100 to a communications network 126 via afirst communications link 128. A server 130 is coupled to thecommunications network via a second communications link 132. In thepresent example, the communications network is the Internet and so thecontroller 100 is capable of communicating packets of data with theserver 130 which are routed through the Internet to a remote monitor.

Referring to FIG. 4, in another embodiment a packaging system 400comprises a packaging machine 401 to which a first servo-motor 402, asecond servo-motor 404 and a third servo-motor 406 are coupled. A firstdriver unit 408, a second driver unit 410 and a third driver unit 412are coupled to the first, second and third servo-motors 402,404,406respectively. In this example, the first, second and third driver units408,410,412 are SAM Smart Digital Drives of the type manufactured byInmotion™. Technologies, although it will be appreciated that othersuitable drivers can be used.

Each of the first, second and third driver units 408,410,412 is coupledto a data bus 413, the data bus 413 also being coupled to a drivermanagement unit 414. In this example, the driver management unit 414 isa Programmable Axis Manager (PAM) manufactured by Inmotion™Technologies, although it will again be appreciated that any suitabledriver management equipment can be employed.

The PAM 414 supports a real-time task 415 that periodically samples adriving signal issued by any one or more of the first, second or thirddriver units 408,410,412 respectively to the first, second or thirdservo-motors 402,404,406. The task 415 is activated, for example, every10 ms if a sampling frequency of, for example, 100 Hz is required. Thedriving signals sampled by the task 415 also correspond to torque of therespective servomotor.

The PAM 414 is coupled to a Local Area Network (LAN) 416, the LAN 416being coupled to a Programmable Logic Controller 418 and a supervisingcomputer 420. In this example, the supervising computer 420 is aPersonal Computer (PC).

Referring to FIG. 5, the supervising computer 420 comprises a processingunit or processor 500, to which one or more input device 502, such as akeyboard and/or a mouse, and an output device 504 such as a display, arecoupled. The processor 500 is also coupled to an Input/Output (I/O) port506, the I/O port 506 being coupled, in this example, to a port (notshown) of the LAN 416.

A first storage device, for example a volatile memory, such as RandomAccess Memory (RAM) 508, is coupled to the processor 500. A secondstorage device, for example a non-volatile memory, such as Read OnlyMemory (ROM) 510, is also coupled to the processor 500. As is commonwith most PCs, the processor 500 is also coupled to a third, re-writablenon-volatile, storage device, for example, a so-called hard drive, orHard Disc Drive (HDD) 512. The hard drive 512, in this example, stores,inter alia, a first database 514, a second database 516, and a thirddatabase 518. However, content of the first, second and third databases514,516,518 need not be stored in a formal database structure providedby many well-known software packages, and can instead be stored, forexample, as a simple look-up table.

In operation (FIGS. 6 and 7), the supervising computer 420 supports amonitoring cycle and a diagnosis cycle in order to identify abnormaloperation of the packaging machine 401 or potential abnormal operationof the packaging machine 401.

With respect to FIG. 6, the supervising computer 420 identifies andselects (step 600) the first servo-motor 402 from the first, second andthird servo-motors 402,404,406 to monitor over a predetermined period oftime at a predetermined sampling rate. The supervising computer 420 theninterrogates the PAM 414 for samples of a first driving signal issued tothe first servomotor 402. The samples of the first driving signalobtained by the task 415 (step 602) are then communicated to thesupervising computer 420, the first driving signal issued to the firstservo-motor 402 by the first driver unit 406 corresponding to firsttorque exerted by the first servo-motor 402. Similarly, a second drivingsignal and a third driving signal respectively issued by the second andthird driving units 408,410 respectively correspond to second and thirdtorques exerted by the second and third servo-motors 404,406.

The sample of the first driving signal is subsequently stored (step 604)by the supervising computer 420 in the first database 514. After storingthe sample of the first driving signal, the supervising computer 420determines (step 606) if the period over which the first driving signalis sampled has expired. If the period has not expired the supervisingcomputer 420 obtains (step 608) another sample of the first drivingsignal from the PAM 414 in respect of a subsequent sampling period andstores (step 604) this most recent sample.

If the period over which the driving signal is sampled has expired, thesupervising computer 410 determines (step 610) if driving signalsimposed upon other servomotors, such as the second or third servomotors404,406 need to be sampled. If, in this example, the second or the thirdservo-motor 404,406 still needs to be monitored, the supervisingcomputer 420 selects (step 612) one of the second or the thirdservo-motors 404,406 for monitoring. The above-described samplingprocedure is then repeated for the driving signal issued to the nextselected servomotor. Indeed, the above process of selection ofservomotors is repeated until all of the servomotors have beenmonitored. The above monitoring procedure is then repeated after apredetermined period of time.

As would be appreciated by one skilled in the art in the context of thisexample, an actual sampling period T_(a), is imposed by the PAM 414, theactual sampling frequency being different from a requested, or expected,sampling period T_(e), requested by the supervising computer 420. Thedifference between the actual and expected sampling periods T_(a),T_(e), is attributable to the fact that the actual sampling period,T_(a), set by the PAM 414 depends upon the priority of the real-timetask 415 and the loading imposed upon the PAM 414 by the variousservo-motors that the PAM 414 manages. However, it is possible tocorrect for the difference between the actual and expected samplingperiods T_(a), T_(e), by calculating a correction factor, α, therebyproviding a way of maintaining accuracy of the samples of the drivingsignals of each servo-motor.

In this respect, for a given servo-motor, the actual sampling period,T_(a) can be expressed in terms of the correction factor, . alpha., andthe expected sampling period T_(e):

T_(a)=. α.T_(e)  (1)

Additionally, the actual position, P_(a), of the given servo-motor canbe expressed in terms of an expected speed V_(e) of the givenservo-motor and the actual sampling period, T_(a) as a function of asampling period number, k:

P _(a)(k)=V _(e) . T _(a) . k  (2)

Substituting equation (1) into equation (2), the actual position P_(a)can be expressed in terms of the expected sampling period, T_(e), andthe correction factor, α:

P _(a)(k)=V _(e) α. T _(e) ·k  (3)

Since a duration, t, of the sampling period number, k, is:

t=k. T _(e)  (4)

By substituting equation (4) into equation (3), the actual position,P_(a), can be expressed as a function of time, t:

P _(a)(t)=V _(e) αt  (5)

Differentiating equation (5) with respect to time provides an expressionfor the actual speed, V_(a), of the given servo-motor:

$\begin{matrix}{\frac{{P_{a}(t)}}{t} = {{V_{e}\alpha} = V_{a}}} & (6)\end{matrix}$

Consequently, by rearranging equation (6), it can be seen that thecorrection factor, α, is the quotient of the actual speed, V_(a), andthe expected speed, V_(e).

Since the actual position, P_(a), is obtained from the PAM 414, theactual speed, V_(a), can be calculated as explained above. Furthermore,since the expected speed, V_(e), is also known, the correction factor,α, can be calculated for correction of samples of the driver signals.

In this respect, the previously sampled driving signals stored in thefirst database 514 are analyzed in the diagnosis cycle (FIG. 7) on amotor-by-motor basis. Hereinafter, for the purpose of simplicity andclarity of description, the diagnostic cycle will be described withrespect to the sample of the driver signal corresponding to the firstservo-motor 402. However, it should be appreciated that the same cyclecan, and is the case in this example, be applied to samples of driversignals issued to other servo-motors, for example, the second and/orthird servo-motors 404,406.

Initially, the samples of the first driver signal (hereinafter referredto as the “first samples”) issued to the first servo-motor 402 areretrieved from the first database 514 stored on the hard drive 512 andpre-processed (step 700) by applying the above-described correctionfactor, α, calculated in accordance with the above equations, to thefirst samples.

Once pre-processed, the pre-processed first samples are subjected tospectral analysis by a spectrum analyzer module (not shown) supported bythe supervising computer 420. In this example, the processor 500 carriesout (step 702) a Fast Fourier Transfer (FFT). The FFT of thepre-processed first samples yields a spectrum which reveals muchinformation not only about the operation of the first servo-motor 402,but also one or more mechanical element coupled directly, or indirectly,to the first servo-motor 402. In this, and other, examples, asub-assembly of the packaging machine 401 comprises the one or moremechanical element.

If required, filters can be used to “clean-up” sampled driver signals soas to facilitate improved accuracy of spectral analysis.

Following generation of the spectrum for the pre-processed firstsamples, the second database 516 is interrogated to obtain information(step 704) relating to one or more relevant parameter extractable fromthe spectrum by analysis thereof, and corresponding to one or more knowncause of abnormal operation of the packaging machine 401. In thisexample, for a given sub-assembly associated with the spectrum, dryfriction, oily friction, sprocket engagement frequency, and lugfrequency are parameters for which values corresponding to theseparameters can be ascertained from the spectrum. Consequently, for agiven parameter such as dry friction, the second database 516 comprisesa list of a predetermined number of frequencies, the respectiveamplitudes at these predetermined number of frequencies characterizingdry friction for a particular mechanical element or elements. Once therelevant parameters along with the identity of one or more frequencycharacteristic of each relevant parameter have been obtained from thesecond database 516, the amplitude(s) at the identified one or morefrequency is/are determined from the spectrum and stored (step 704) inthe second database 516.

Subsequently, the amplitudes for each frequency stored are retrievedfrom the second database 516 along with inference rules from the thirddatabase 518. Using the inference rules, fuzzy logic is respectivelyapplied (step 706) to each amplitude retrieved. Clearly, if a givenamplitude has been stored more than once in the second database 516 inrelation to more than one parameter, the given amplitude need only betested once, if required, by a corresponding given influence rule.

The results of the application of the fuzzy logic yield a determinationof abnormal operation of one or more mechanical element of the givensub-assembly and, where abnormal operation is occurring, identificationof one or more mechanical element believed to be the source of theabnormal operation.

Alternatively, instead of applying fuzzy logic, the amplitudes for eachfrequency stored in the second database 516 can be compared withempirically derived characterizations of the parameters being monitored,the empirically derived characteristics being stored in the thirddatabase 518. The empirically derived characterizations can be stored asranges of acceptable values. As a further alternative, thecharacterizations can be learnt.

Upon detection of abnormal operation, information relating to theabnormal operation of the packaging machine 401 can be communicated to aservice engineer, for example, via the display 504. Additionally, oralternatively, the supervising computer 420 can issue an instruction tothe PLC 418 to activate the auto-correction device, such as themicro-sprayers attached to the packaging machine 401 in order to providecorrective maintenance to the one or more mechanical element to causethe packaging machine 401 to revert to a state of normal operation.Other corrective, or preventative, measures already described above inprevious examples can also be employed.

Alternative embodiments of the invention can be implemented as acomputer program product for use with a computer system, the computerprogram product being, for example, a series of computer instructionsstored on a tangible data recording medium, such as a diskette, CD-ROM,ROM, or fixed disk, or embodied in a computer data signal, the signalbeing transmitted over a tangible medium or a wireless medium, forexample microwave or infrared. The series of computer instructions canconstitute all or part of the functionality described above, and canalso be stored in any memory device, volatile or non-volatile, such assemiconductor, magnetic, optical or other memory device.

1. A system for monitoring the condition of a packaging machine duringoperation and diagnosing potential problems in the performance of themachine, the system comprising: an input device, an output device, and aprocessing unit that supports a user interface, the processing unitbeing arranged to permit a user, when in use, to input via the inputdevice a number of parameters indicative of predetermined levels andconditions of performance of one or more elements or assemblies in themachine, to receive current information from one or more sensorsmeasuring signals corresponding to torques of servo-motors indicating anactual level and condition of performance of the element or assembly, toreceive and permit listening of sounds as detected by at least one noisedetection device wherein said detected sounds are associated with anidentifiable machine element, to receive and make available forretrieval visual information in the form of images of at least oneoperating machine element recorded by at least one image-recordingdevice and to compare the current information with the parameter torender via the output device an output signal.
 2. The system as claimedin claim 1, wherein the output signal is a warning message displayed onthe output device.
 3. The system as claimed in claim 1, wherein theoutput signal actuates an auto-correction device.
 4. The system asclaimed in claim 1, wherein the output signal is a message warning theoperator about scheduled maintenance.
 5. A programmed computer forgenerating control data for controlling a packaging machine, comprising:memory having at least one region for storing computer executableprogram code, and a processor for executing the program code stored inthe memory, wherein the program code includes: code to receive currentinput data of servo-motor signals measured by one or more sensorsmonitoring an element or assembly of the machine indicating conditionsand levels of performance of the element or assembly; code to generate acomparison between the current input data and stored data ofpredetermined values of noise detected by, visual information recordedby and servo-motor signals measured by the one or more sensors; code togenerate output data for the packaging machine when the input data doesnot correspond to the stored data; code to receive and permit listeningof sounds as detected by at least one noise detection device whereinsaid detected sounds are associated with an identifiable machineelement; and code to receive and make available for retrieval from atleast one storage medium visual information in the form of images of atleast one operating machine element recorded by at least oneimage-recording device.